Method and apparatus for preparing a finished tobacco product including a sheet with a set of perforations for sealing the tobacco product

ABSTRACT

A finished tobacco product is formed by a pre-rolled smokable sheet having opposed edges with one of the edges having a plurality of openings for effecting a seal without additional adhesive or glue, pulling apart the opposed edges, filling the exposed bore or volume with a user&#39;s selected tobacco filler, allowing the rolling memory to close the bore or volume and contain the tobacco filler, bringing together the opposed edges such that the plurality of openings on one edge extends over the opposed edge, pushing together the two edges causing a seal, where the plurality of openings on one of the opposing edges of the pre-rolled sheet is used to effect the seal without additional glue or adhesive.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of U.S. Patent Application Ser. No. 61/872,369, filed Aug. 30, 2013, which application is incorporated herein by reference and to which priority is hereby claimed.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND

The variety, quality and size of ready-made cigars and/or cigarillos satisfy the majority of the public. However, a small segment of connoisseurs insist that nothing can compare with the taste and smell of custom-blended tobacco products. These knowledgeable individuals are very selective in the manner their tobacco products are rolled and in the grade of tobacco used. A still smaller segment of aficionados prefers to roll their own tobacco products. They buy tobacco leaves or cigar wrappings and use their preferred brand of crushed tobacco. Some people buy inexpensive cigars, cut them with a sharp blade along the side, and carefully pry the cut cigar open. The innermost layers are then removed and substituted with a favorite brand of crushed tobacco, which may come from cigarettes or bulk tobacco blend. The user then brings the cut edges of the cigar together, closing the outer layers of the cigar over the “stuffing.” The edges are then sealed with a liquid or honey, and a new cigar is ready for smoking.

Some reports indicate that the roll-your-own tobacco market is flourishing. In some countries, the roll-your-own products now hold a substantial share of the tobacco market, and their consumers represent more than 10% of the smoking population. This may be explained by the ability of a consumer to create a tailor-made product, as opposed to commercially available types of tobacco products.

A disadvantage of the existing method of making such custom-made tobacco product is that a consumer has to be skillful in the rolling of tobacco products, that is to have a certain finger dexterity, which would allow him to make a tobacco product shell without crushing the item being used to make the tobacco product. Inexperienced people often become frustrated when the finished product collapses because the tobacco product was not properly rolled.

In the prior art there are various items which assist consumers in making customized cigars. For example, in U.S. Pat. No. 6,742,525 discloses a “tobacco product . . . formed by rolling a sheet of material supplied by a roll or rolls (e.g. moistened tobacco leaves) and/or homogenized sheet tobacco about a slit mandrel to form a shaped tube. The shaped tube is then packaged for shipment to an end user or consumer. The shaped tube remains in the rolled, shaped tube form inside the package. After the shaped tube is removed from the package, a consumer can fill the tube with crushed tobacco leaves or other tobacco filler material of a favorite blend, thereby eliminating some steps in the making of a “roll-your-own” tobacco product.” ('525 patent: Abstract).

However, this prior art system has limited amount of sealing the shaped tube and in many instances requires the cigar glue or adhesives to form the seal in making the custom cigar. Additionally, these prior art systems tend to require the user to seal the rolled tobacco product along the longitudinal length of the tobacco product to stop the product.

It would be advantageous to provide a tobacco product which avoids the disadvantages of the prior art.

While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”

BRIEF SUMMARY

In one embodiment the pre-rolled smokable sheet includes binder and wrapper layers with a plurality of openings (but no glue or adhesive in connection openings) for assisting with sealing of a custom made finished cigar or cigarillo.

In one embodiment the pre-rolled smokable sheets are comprised of homogenized tobacco paper.

In one embodiment the pre-rolled smokable sheets are comprised of natural leaves.

In one embodiment the pre-rolled smokable sheets are comprised of smokable materials.

In various embodiments the pre-rolled smokable sheets are comprised of smokable materials chosen from any combination of the following materials: natural leaf, homogenized tobacco paper, pipe tobacco, different types of flavored tobacco, cellulose (clear, opaque, or colored), paper, cigarette paper, rice paper, tea leaves, kanna, blue lotus, salvia, salvia eivinorm, wild dagga, kratom, herbal non-tobacco, Celandine Poppy, Mugwort, Purple Lavender Flowers, Coltsfoot Leaf, Ginger root, California Poppy, Sinicuichi, St. John's Wort, Capillarius herba, Yerba Lenna Yesca, Calea Zacatechichi, Leonurus Sibericus Flowers, Wild Dagga Flowers, Klip Dagga Leaf, Damiana, Hookah, Hemia salicifolia, Kava Kava, Avena Sativa, scotch broom topps, Valarian, capillarius, herba, Wild clip dagga, Leonurus sibiricus, Kanna, Sinicuichi, and/or lactuca virosa.

In various embodiments the tobacco filler material used to make the custom cigar or cigarillo is selected from any combination of the following types of filler material: smoking tobacco, pipe tobacco, different types of flavored tobacco, tea leaves, kanna, blue lotus, salvia, salvia eivinorm, wild dagga, kratom, herbal non-tobacco, Celandine Poppy, Mugwort, Purple Lavender Flowers, Coltsfoot Leaf, Ginger root, California Poppy, Sinicuichi, St. John's Wort, Capillarius herba, Yerba Lenna Yesca, Calea Zacatechichi, Leonurus Sibericus Flowers, Wild Dagga Flowers, Klip Dagga Leaf, Damiana, Hookah, Hemia salicifolia, Kava Kava, Avena Sativa, scotch broom topps, Valarian, capillarius, herba, Wild clip dagga, Leonurus sibiricus, Kanna, Sinicuichi, and/or lactuca virosa.

One embodiment provides various configurations of additional pre-rolled sheets having similar plurality of openings and no glue or adhesive on their edges. One embodiment includes a layered configuration of pre-rolled sheets including a first sheet of homogenized tobacco paper, a second sheet of natural leaf, and a third sheet of homogenized tobacco paper. One embodiment includes a layered configuration of pre-rolled sheets including a first sheet of natural leaf, a second sheet of homogenized tobacco paper, and a third sheet of natural leaf One embodiment includes a plurality of additional pre-rolled sheets numbering 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30. Various embodiments include possible ranges between any of the combinations of the above listed numbers. For example, between 3 and 20, 5 and 15, etc.

One embodiment additional pre-rolled includes sheets with pluralities of openings on their edges, the sheets being made of the same material, such as homogenized tobacco paper, natural leaf, rolling paper, and/or sheets of other smokable materials. One embodiment includes possible combinations of the different types of sheets of homogenized tobacco paper, natural leaf, rolling paper, and/or sheets of other smokable materials. One embodiment includes sheets comprised of different smokable materials chosen from any combination of the following types of materials: natural leaf, homogenized tobacco paper, pipe tobacco, different types of flavored tobacco, tea leaves, kanna, blue lotus, salvia, salvia eivinorm, wild dagga, kratom, herbal non-tobacco, Celandine Poppy, Mugwort, Purple Lavender Flowers, Coltsfoot Leaf, Ginger root, California Poppy, Sinicuichi, St. John's Wort, Capillarius herba, Yerba Lenna Yesca, Calea Zacatechichi, Leonurus Sibericus Flowers, Wild Dagga Flowers, Klip Dagga Leaf, Damiana, Hookah, Hemia salicifolia, Kava Kava, Avena Sativa, scotch broom topps, Valarian, capillarius, herba, Wild clip dagga, Leonurus sibiricus, Kanna, Sinicuichi, and/or lactuca virosa.

In various embodiments supporting form casings can be comprised of one or more of the following materials or combinations of materials: filter material, sponge, cotton, paper, cardboard, wood, metal, tobacco, hemp, hemp paper, clove, mir, willow bark, dogwood cornus sp, red osier, pipsissewa, chimaphila, pyrola, kinnikinnik, arctostaphylos uva-ursi, camomile herbs, manzanita, shrubby arctostaphylos sp, madrone, arbutus menziesii, blackberry, rubus sp, scotch broom, cytisus, scoparius, cannabis, hemp THC-free, calamus, mullein, and/or verbascum thapsus. In various embodiments form casings can be comprised of sticks, tobacco sticks, and/or pipe cleaners.bark, In one embodiment filter material can be comprised of acetate, paper, plastic, polymer, cotton, charcoal, and/or a combination of one or more of the specified materials.

One embodiment of the method enables an end user to make his or her own custom finished tobacco products with a selected, custom filler material/blend of filler material. The method preferably includes the use of a liquid for moisturizing, and also preferably includes flavoring and/or scenting. The liquid can be, in whole or in part, water, alcohol, solvent, oil, propylene glycol, ethyl alcohol, glycerin, benzyl alcohol as examples. The liquid can be flavored and/or scented with items such as for example apple, apple martini, berries, blueberry, champagne, chocolate, coco/vanilla, cognac, cosmo, gin, grape, honey, lychee, mango, menthol, mint choco, peach, piña colada, punch, purple, rum, strawberry/kiwi, vanilla, watermelon, wet cherry, and/or whiskey.

The flavors are preferably added to the form casings and/or pre-rolled sheets with a liquid. This flavored liquid is typically applied at levels of between about 0.01 to 45% by weight, and preferably between about 0.1% to 10% by weight. This flavored liquid is typically applied to the at least one pre-rolled sheet with a carrier liquid such as ethyl alcohol, propylene glycol, water or the like. Glycerin and invert sugar can also be used as a carrier. Some humectants can also be used, however, little or no humectants can be used. In general terms, the flavors can be provided by botanical extracts, essential oils, or artificial flavor chemicals, any one of which or a combination thereof mixed with a carrying solvent such as propylene glycol, ethyl alcohol, glycerin, benzyl alcohol, or other alcohol, for example. Other flavors can include cocoa, licorice, coffee, vanilla or other botanical extracts. Essentials oils can be used such as wine essence, cognac oil, rose oil, mate or other oils.

In various embodiments instructions can be provided with the packaging (or on the packaging) showing one or more of the steps of unrolling a pre-rolled sheet, filling the interior volume with a consumer's custom tobacco filler material, and closing the inner shell using the plurality of openings to create a seal between the opposed edges of the pre-rolled sheet to form a custom made cigar or cigarillo.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the drawings, wherein like parts are designated by like numerals, and wherein:

FIG. 1 is a top view of one embodiment of a smokable sheet having a plurality of sealing openings where the openings extend the length of the sheet and to a specified depth.

FIG. 2 is a top view of one embodiment of a smokable sheet having a plurality of sealing openings where the openings extend to a specified depth, but do not extend the length of the sheet on at least one side.

FIG. 3 is a perspective view of a plurality of flat smokable sheets of the FIG. 1 construction with at least one intermediate separating sheet between two of the smokable sheets.

FIG. 4 is a perspective view of a plurality of pre-rolled smokable sheets of the FIG. 1 construction with at least one intermediate separating sheet between two of the smokable sheets, where the plurality of smokable pre-rolled sheets are supported by a form mandrel.

FIG. 5 is a perspective view of two sets of pluralities of pre-rolled smokable sheets of the construction shown in FIG. 4 which are both packaged for sale.

FIG. 6 is a close up perspective view of the plurality of pre-rolled smokable sheets of FIG. 4.

FIG. 7 is a close up perspective view of the plurality of pre-rolled smokable sheets of FIG. 4, where portions of the outer pre-rolled smokable sheet and outer separating sheet have been removed to better see the inner pre-rolled smokable sheets and separating sheets.

FIGS. 7 through 10 are perspective views illustrating the steps of opening creating a custom cigar or cigarillo from one of the pre-rolled sheets of FIG. 1.

FIG. 8 is a perspective view of a pre-rolled sheet removed from the form mandrel, with the edges of the sheet being pulled apart to open the bore, tobacco filler material being placed in this inner bore or volume, and the pre-rolled sheet having a memory tending to cause it to roll back up thereby closing the inner bore and confining the tobacco filler material.

FIG. 9 schematically indicates that the sheet is rolled with the tobacco filler material in the inner volume such that the plurality of openings are placed over the opposing edge of the pre-rolled sheet to cause the edges to seal together.

FIG. 10 is a perspective view of the custom made finished cigar or cigarillo which is now ready to smoke.

FIG. 11 is a close up perspective view of the finished custom cigar or cigarillo where a portion of the outer edge of the pre-rolled smokable sheet has been removed to better see the opposed edge of the pre-rolled smokable sheet, and that the plurality of openings seal over the opposed edge of the pre-rolled smokable sheet.

FIG. 12 is a top view of the finished cigar or cigarillo of FIG. 10.

FIG. 13 is a top view of one embodiment of a smokable sheet having a plurality of sealing openings on a plurality of sealing tabs where the tabs.

FIG. 14 is a top view of another embodiment of a smokable sheet having a plurality of sealing openings on a sealing tab on the left hand side of the sheet.

FIG. 15 is a top view of another embodiment of a smokable sheet having a plurality of sealing openings on a sealing tab on the right hand side of the sheet.

FIG. 16 is a top view of another embodiment of a smokable sheet having multiple sets of spaced apart groupings of plurality of sealing openings on a longer side of a rectangular sheet.

FIG. 17 is a top view of another embodiment of a smokable sheet having multiple sets of spaced apart groupings of plurality of sealing openings on a shorter side of a rectangular sheet.

DETAILED DESCRIPTION

Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner. Reference will now be made to the drawings, wherein like parts are designated by like numerals.

Sheet 100 can be comprised of smokable materials chosen from any combination of the following materials: natural leaf, homogenized tobacco paper, pipe tobacco, different types of flavored tobacco, cellulose (clear, opaque, or colored), paper, tea leaves, kanna, blue lotus, salvia, salvia eivinorm, wild dagga, kratom, herbal non-tobacco, Celandine Poppy, Mugwort, Purple Lavender Flowers, Coltsfoot Leaf, Ginger root, California Poppy, Sinicuichi, St. John's Wort, Capillarius herba, Yerba Lenna Yesca, Calea Zacatechichi, Leonurus Sibericus Flowers, Wild Dagga Flowers, Klip Dagga Leaf, Damiana, Hookah, Hernia salicifolia, Kava Kava, Avena Sativa, scotch broom topps, Valarian, capillarius, herba, Wild clip dagga, Leonurus sibiricus, Kanna, Sinicuichi, and/or lactuca virosa.

FIGS. 4, 6, and 7 are perspective views of a plurality of pre-rolled sheets 100, 100′, and 100″ wrapped about form mandrel 600. Arrow 430 in FIG. 6 schematically represents the step of rolling in creating the pre-rolled condition of the pre-rolled sheets. In different embodiments, pre-rolled sheet 100′ and/or 100″ can be omitted. During the rolling process form mandrel 600 serves as a casing or form mandrel for pre-rolling sheets 100, 100′, and 100″. When sheet 100 is so pre-rolled (schematically indicated by arrow 440 in FIG. 7), after being unrolled it will have a “rolling memory” tending to cause it to roll up again and assisting in the process of making a custom made cigar or cigarillo. The action of the “rolling memory” and “rolled memory” better assists an individual in making a custom made cigar or cigarillo. The process of making a custom made cigar or cigarette will be described below.

Pre-rolled sheets 100, 100′, and 100″ can be placed in packaging for sale, such as that shown in FIG. 5. Also alternatively, intermediate (and unattached) sheets 200, 200′, and/or 200″ can be placed respectively on the lower surfaces 104,104′,104″ of sheets 100, 100′, 100″ to prevent sheets 100,100′, 100″ from sticking to themselves or other sheets (e.g., 100′, 100″, etc.). These intermediate sheets 200,200′,200″ can be of a construction to serve as a moisture barrier, and preferably be about the same size as sheets 100,100′,100″, but would not be connected to the sheets. This intermediate sheets 200, 200′, 200″ assist in the unrolling process of sheets 100,100′,100″ from form mandrel 600. Additionally, these intermediate sheets 200,200′,200″ inhibit moisture loss from the sheets.

When making custom cigar 800, the intermediate sheet 200 would be removed and discarded after sheet 100 was unrolled from form case 600 (and respectively intermediate sheet 200′ from sheet 100′, and sheet 200″ from sheet 100″). If intermediate sheet 200 is used, it should be removed before making custom cigar or cigarillo 800 from sheet 100 because sheet 200 is not smokable.

Plurality of openings 1000 along a substantial portion of the longitudinal length of sheet 100 assists users (compared to no openings) in sealing spaced apart edges of sheet 100 (e.g., edges 120 and 140 in forming the custom made cigar or cigarillo 800 after custom cigar or cigarillo 800 has been filled with tobacco filler material 22). FIG. 2 is a perspective view of another alternative embodiment of smokable sheet 300 having irregularly shaped openings 2000 along its longitudinal length of one side 320.

FIGS. 1 and 2 show various embodiments for plurality of openings 1000 in connection with their placement on smokable sheets.

In various embodiments plurality of openings 1000, 2000, 2200, and 2300 should preferably have an average size of less than or equal to one millimeter. In different embodiments the average size of the openings can range between about 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.2, 1.4, 1.5, 1.6, 1.8, and 2 millimeters. In various embodiments the average size of the openings can range between about any two of the above specified average sizes.

In various embodiments plurality of openings 1000, 2000, 2200, and 2300 can preferably be arranged in rows. In different embodiments the number of rows can be at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and/or 20. In various embodiments the number of rows can range between any two of the above specified number of rows.

In various embodiments plurality of openings 1000, 2000, 2200, and 2300 can preferably be arranged in columns. In different embodiments the number of columns can be at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, and/or 100. In various embodiments the number of columns can range between any two of the above specified number of columns.

In various embodiments plurality of openings 1000 can be located adjacent one edge of sheet 100 (e.g., edge 120) and extend away from such edge a defined amount (e.g., along edge 110 and dimension 114) leaving the remaining portion of sheet 100 without openings (e.g., along dimension 116). In various embodiments plurality of openings 1000 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and/or 60 percent of sheet 100's height (e.g., length 112). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent 114 of plurality of opening 1000 extend along the height 112 of sheet 100. In FIG. 1, the extent that plurality of openings extend along height 112 can be represented by dimension 114, and the extent of height not occupied by plurality of openings 1000 can be represented by dimension 116. Dimension 116 added to dimension 114 equals dimension 112, representing the full height of edge 110.

In various embodiments plurality of openings 1000 can cover the entirety of sheet 100 for both length (e.g., dimension 122) and width or height (e.g., dimension 112).

In various embodiments plurality of openings 1000 can be located adjacent one edge of sheet 100 (e.g., edge 120) and extend along a substantial portion (although not its entire longitudinal length). In various embodiments plurality of openings 1000 can extend about 50, 55, 60, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, and/or 100 percent of sheet 100's longitudinal length (e.g., length 122). In various embodiments ranges between any of the two above specified percentages can be used for opening the longitudinal length.

FIG. 2 is a top view of smokable sheet 300 having a plurality of sealing openings 2000 where the openings 2000 extend a portion of the longitudinal length 326, but do not extend the entire length 322 of sheet 300 on at least one side (dimension 324 on edge 330 and/or dimension 328 on edge 310).

Similar to the embodiment of plurality of openings 1000 for sheet 100, in various embodiments plurality of openings 2000 can extend about 5, 10, 15, 20, 25, 30, and/or 33 percent of sheet 300's height (e.g., length 312). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent 314 of plurality of openings 2000 extend along the height 312 of sheet 200.

In various embodiments plurality of openings 2000 (in FIG. 2 schematically indicated by dimension 326) can extend about 50, 55, 60, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, and/or 100 percent of sheet 300's longitudinal length (e.g., length 322). In various embodiments ranges between any of the two above specified percentages can be used for dimension 326 for plurality of openings 2000 along longitudinal length 322.

In various embodiments no additional cigar glue or adhesive is contained in the area of the plurality of openings 1000.

In one embodiment, intermediate sheets 200,200′,200″ can be placed above or below smokable sheet 100, or between two smokable sheets 100, 100′, or between three smokable sheets 100, 100′, and 100″. Intermediate sheets can be comprised of Low & High Density Polyethylene with EVA additive, Linear Low Density Poly, Polypropylene, Orientated Polypropylene, Cast Polypropylene, PVC, Polyester, Vaper Barrier packaging, Moisture Barrier packaging, Laminated packaging, Shrink film, Stretch Film, Foil Films, Metalized Film, Cellophane, and Polyethylene Terephthalat.

Packaging 700 can include, but are not limited to, Low & High Density Polyethylene with EVA additive, Linear Low Density Poly, Polypropylene, Orientated Polypropylene, Cast Polypropylene, PVC, Polyester, Vaper Barrier packaging, Moisture Barrier packaging, Laminated packaging, Shrink film, Stretch Film, Foil Films (which can be translucent or opaque), Metalized Film, Cellophane, and Polyethylene Terephthalat. In addition to an “EVA” additive a barrier foil lamination can be used being either coated or metallized. The packaging, whether plastic, aluminum, or glass, keeps moisture in or dramatically slows down moisture loss from the pre-rolled sheet(s). It is preferable that the wrapping material have adequate moisture resistant properties so that the tobacco product does not dry out before use by consumers.

The packaging can have indicia which provides consumers with information concerning the sets of tobacco products, such as flavoring, scent, moisture, or other information. The carton can itself be covered by wrapper.

FIGS. 4-7 show the use of a non-smokable form casing 600 which can be used to support pre-rolled smokable sheet 100. Form mandrel 600 can be comprised of a rigid or flexible material in a form of a cylinder of a predetermined length and outer diameter. Form casing/mandrel 600 can be made either hollow, with a central opening, or as a solid body. It is desirable that form casing/mandrel 600 be substantially inflexible and strong enough to withstand forces applied to form casing/mandrel 600 when the unit is shipped to its ultimate selling outlet, and when pre-rolled smokable sheet 100 unrolled from form casing/mandrel 600. In various embodiments form casing 600 can be comprised of one or more of the following materials or combinations of materials: filter material, sponge, cotton, paper, cardboard, wood, metal, tobacco, hemp, hemp paper, clove, mir, willow bark, dogwood cornus sp, red osier, pipsissewa, chimaphila, pyrola, kinnikinnik, arctostaphylos uva-ursi, camomile herbs, manzanita, shrubby arctostaphylos sp, madrone, arbutus menziesii, blackberry, rubus sp, scotch broom, cytisus, scoparius, cannabis, hemp THC-free, calamus, mullein, and/or verbascum thapsus. In various embodiments form casing 600 can be comprised of sticks, tobacco sticks, and/or pipe cleaners. In one embodiment filter material can be comprised of acetate, paper, plastic, polymer, cotton, charcoal, and/or a combination of one or more of the specified materials. In one embodiment, form casing 600 can include two layers (inside and outside layers). The layers can be comprised of an aluminum/polymer/non-smokable outside layer and tobacco filler inside layer.

FIGS. 5 and 7 through 12 illustrate the steps in one embodiment for making a custom made cigar or cigarillo using pre-rolled sheet 100.

FIG. 8 is a perspective view of a pre-rolled sheet 100 removed from the form mandrel 600, with the edges 120,140 being pulled apart to open the bore 410, tobacco filler material 22 being placed in this inner bore or volume 410, and the pre-rolled sheet 100 having a memory tending to cause it to roll back up thereby closing the inner bore 410 and confining the tobacco filler material 22.

FIG. 9 schematically indicates that the sheet 100 is rolled with the tobacco filler material 22 in the inner volume 410 such that the plurality of openings 1000 are placed over the opposing edge 140 of the pre-rolled sheet 100 to cause the overlapping edges 120,140 to seal together.

FIG. 11 is a close up perspective view of the finished custom cigar or cigarillo 800, with arrows 70,71, and 72 schematically indicating the application of moisture top side of plurality of openings 100, and where a portion of the outer edge 120 of the pre-rolled smokable sheet 100 has been removed to better see how the opposed edge 140 seals the plurality of openings 1000. FIG. 12 is a top view of the finished cigar or cigarillo 800 also showing that the opposed edge 140 of the pre-rolled smokable sheet 100 seals the openings 1000.

The first step would be to remove smoking apparatus 400 from packaging or pouch 700 (see FIGS. 5 and 7), and then remove pre-rolled smokable sheet 100 from form casing 600 (schematically shown by arrow 440 in FIG. 7). FIG. 8 is a perspective view of the step of filling pre-rolled smokable sheet 100 with a user's custom selected tobacco filler 20. Smokable sheet 100 can have its edges 120 and 140 pulled/spaced apart by a user (schematically indicated by arrows 53 and 54) to better expose inner bore or volume 410. Next, the step of adding a selected custom tobacco filler 20 material to bore or volume 410 (schematically indicated by arrow 22), and releasing edges 120,140 so that the rolling memory of sheet 100 tends to roll itself (schematically indicated by arrows 55 and 56) back around the tobacco filler in bore or volume 410. Arrows 55 and 56 schematically indicate the “rolling memory” of smokable sheet 100 wherein this rolling memory tends to cause edges 120 and 140 to move back towards one another (when edges 120 and 140 are moved apart). Such “rolling memory” greatly assists in the re-rolling process—after custom tobacco filler material 22 has been added to inner bore or volume 410.

FIGS. 8 through 12 are perspective views illustrating the steps of, following the addition of the selected tobacco filler material 22 (schematically shown in FIG. 8), then moving closer edges 120 and 140 of smokable sheet 100 to enclose tobacco filler material 22 now contained in exposed inner bore or volume 400 of smokable sheet (schematically indicated by arrows 55 and 56 in FIG. 8 where, in moving closer edges 120 and 140, beyond any rolling memory, a user can use his hands and fingers which user is not shown). Edges 120 and 140 will continue to be moved closer together (schematically indicated by arrow 60 in FIG. 9), and then pass each other causing outer smokable sheet 100 to at least partially overlap itself when closing interior bore or volume 410, such that the extent of plurality of openings 1000 (indicated by dimension 114) overlap edge 140 and edge 140 seals plurality of openings (shown in FIGS. 10 through 12). The user can apply moisture to edge 140 and/or plurality of openings 1000 to effect a seal between edge 140 and edge 120.

While edges 120 and 140 overlap, moisture can be applied by the user on the outside surface 104 of sheet 100 at the location of the plurality of openings 1000 which applied moisture can travel from outside surface 104, through plurality of openings, and into inside surface 102 of edge 120 along with outside surface 104 of overlapped edge 140, wetting both the underside 102 of edge 120 and top side 104 of edge 140 for effecting a seal between the two edges. Arrows 70,71, and 72 in FIG. 12 schematically indicate the step of applying moisture top side of plurality of openings 1000. Pressure can be applied along such overlapped edge (schematically indicated by arrows 61 and 61 along with the area between these two arrows), to effect a seal between the two overlapping edges. In one embodiment moisture is applied by licking top side plurality of openings 1000.

In one embodiment a set of instructions for wetting top side of the plurality of openings can be provided. FIG. 5 includes instructions 770, which can be printed on packaging 700, instructing the consumer that the plurality of openings are to be wetted topside, and such wetting will migrate through the plurality of openings to seal the overlapping edges. In other embodiments the instructions 770 can be included inside packaging 700.

FIG. 10 is a perspective view of the custom made finished cigar or cigarillo 800 which is now ready to smoke. First end (located at edge 110 of smokable sheet 100) can be lit and second end (located at edge 130 of smokable sheet 100) can be placed in the mouth of the smoker.

FIGS. 13-15 show alternative embodiments of smokable sheet 300 having one or two sealing tabs 370 and/or 380 with plurality of sealing openings 2200 and/or 2300 on such tab or tabs.

FIG. 13 is a top view of one embodiment of a smokable sheet 300′ having a plurality of sealing openings 2200 and 2300 on a plurality of sealing tabs 370 and 380 where the tabs 370 and 380 extends a length 314 beyond the edge 320.

FIG. 14 is a top view of another embodiment of a smokable sheet 300″ having a plurality of sealing openings 2200 on a sealing tab 370 on the left hand side of the sheet (edge 330) where the tab 370 extends a length 314 beyond edge 320.

FIG. 15 is a top view of another embodiment of a smokable sheet 300′″ having a plurality of sealing openings 2300 on sealing tab 380 on the right hand side of the sheet (edge 310) where the tab 380 extends a length 314 beyond edge 320.

In various embodiments plurality of sealing openings 2200 and/or 2300 can be located adjacent one edge of the sheet (e.g., edges 310 or 320) in tabs 370 and/or 380. In various embodiments tabs 370 and/or 380 can extend along a substantial portion (although not its entire longitudinal length) of the sheet. In various embodiments the sets of plurality of sealing openings 2200 and/or 2300 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and/or 60 percent of sheet 300's longitudinal length (e.g., length 322). In various embodiments ranges between any of the two above specified percentages can be used for opening the longitudinal length.

In various embodiments plurality of sealing openings 2200 and/or 2300 can be located adjacent one edge of sheet (e.g., edge 320) and extend away from such edge a defined amount. In various embodiments plurality of sealing openings 2200 and/or 2300 can extend an amount such that the length (e.g., dimension 314) is about 5, 10, 15, 20, 25, 30, and/or 33 percent of sheet 300's height (e.g., length 312). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent 314 of plurality of sealing openings 2200 and/or 2300 extend along the height 312 of sheet 300. In FIGS. 13-15, the extent that plurality of sealing openings 2200 and/or 2300 extend along height 312 can be represented by dimension 314, and the extent of height not occupied by plurality of openings 2200 and/or 2300 can be represented by dimension 316. Dimension 316 added to dimension 314 equals dimension 312, representing the full height of edge 310.

Sheets 300′, 300″, and/or 300′″ can be used in any of the embodiments in the steps described with the other embodiments. However, plurality of sealing openings 2200 and/or 2300 in sealing tabs 370 and/or 380 can be used to seal the finished tobacco product (instead of plurality of sealing openings 1000 or 2000).

As part of the method, the tobacco products disclosed in this application can be sprayed with a liquid that preferably includes a flavoring.

FIG. 16 is a top view of another embodiment of a smokable sheet 100′ having multiple sets of spaced apart groupings of plurality of sealing openings (e.g., 2200 and 2300) this sheet of rectangular shape. It is envisioned that tobacco filler will be added to this sheet 100′ and rolled along its shorter edges (e.g., edges 110 and 130) so that a longer smoking product will be created (of about length of dimension 122).

In various embodiments first plurality of openings 2200 can be located adjacent one edge of sheet 100 (e.g., edge 120) and extend away from such edge a defined amount (e.g., along edge 110 and dimension 114). In various embodiments first plurality of openings 2200 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and/or 60 percent of the height of sheet 100's (e.g., length 112). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent 114 of first plurality of openings 2200 extending along the height 112 of sheet 100′. In FIG. 16, the extent that first plurality of openings 2200 extend along height 112 can be represented by dimension 114.

In various embodiments second plurality of openings 2300 can be spaced apart from first plurality of openings 2200 (represented by dimension 117) and second plurality of openings 2300 can extend along an edge a defined amount (e.g., along edge 110 and dimension 115). In various embodiments second plurality of openings 2300 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and/or 60 percent of the height of sheet 100′ (e.g., length 112). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent 115 of second plurality of openings 2300 extending along the height 112 of sheet 100′. In FIG. 16, the extent that second plurality of openings 2300 extend along height 112 can be represented by dimension 115.

In various embodiments second plurality of openings 2300 can be spaced apart from edge 140 which edge 140 is opposed to edge 120 that first plurality of openings 2200 are located adjacent to. Spacing apart second plurality of openings 2200 from edge 140 is schematically represented by dimension 118. In various embodiments spacing apart dimension 118 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and/or 95 percent of the height of sheet 100′ (e.g., length 112). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent of spacing apart dimension 118 extends along the height 112 of sheet 100′.

In various embodiments second plurality of openings 2300 can be spaced apart from first plurality of openings 2200. Spacing apart second plurality of openings 2200 from first plurality of openings is schematically represented by dimension 117. In various embodiments spacing apart dimension 117 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and/or 95 percent of the height of sheet 100′ (e.g., length 112). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent of spacing apart dimension 117 extends along the height 112 of sheet 100′.

In various embodiments first and second plurality of openings 2200 and 2300 can extend along a substantial portion (although not its entire longitudinal length) of a side (e.g., side 120 and of dimension 122). In various embodiments first and second plurality of openings 2200 and 2300 can extend about 50, 55, 60, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, and/or 100 percent of the longitudinal length of sheet 100′ (e.g., length 122). In various embodiments ranges between any of the two above specified percentages can be used the extension of the plurality of openings.

FIG. 17 is a top view of another embodiment of a smokable sheet 300″″ having multiple sets of spaced apart groupings of plurality of sealing openings on a shorter side of a rectangular sheet. It is envisioned that tobacco filler will be added to this sheet 300″″ and rolled along its shorter edges (e.g., edges 310 and 330) so that a longer smoking product will be created (of about length of dimension 322).

In various embodiments first plurality of openings 2200 can be located adjacent one edge of sheet 300″″ (e.g., edge 330) and extend away from such edge a defined amount (e.g., along edge 320 and dimension 328). In various embodiments first plurality of openings 2200 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and/or 60 percent of sheet 300″″'s length (e.g., length 322). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent 328 of first plurality of openings 2200 extending along the length 322 of sheet 300″″. In FIG. 17, the extent that first plurality of openings 2200 extend along side 320 can be represented by dimension 322.

In various embodiments second plurality of openings 2300 can be spaced apart from first plurality of openings 2200 (represented by dimension 326) and second plurality of openings 2300 can extend along an edge a defined amount (e.g., along edge 320 and dimension 324). In various embodiments second plurality of openings 2300 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, and/or 60 percent of the length of sheet 300″″ length (e.g., length 322). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent (e.g., dimension 324) that second plurality of openings 2300 extend along the length 322 of sheet 300″″. In FIG. 17, the extent that second plurality of openings 2300 extend along side 320 can be represented by dimension 324.

In various embodiments second plurality of openings 2300 can also be spaced apart from edge 310 which edge 310 is opposed to edge 330 that first plurality of openings 2200 are located adjacent to. Spacing apart second plurality of openings 2200 from edge 310 is not schematically shown in FIG. 17. In various embodiments spacing apart dimension of second plurality of openings 2300 from edge 310 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and/or 95 percent of the height of sheet 300′″ (e.g., length 322). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent of spacing apart of second plurality of openings 2300 from edge 310 which spacing apart extends along the height 322 of sheet 300″″.

In various embodiments second plurality of openings 2300 can be spaced apart from first plurality of openings 2200. Spacing apart second plurality of openings 2200 from first plurality of openings is schematically represented by dimension 326. In various embodiments spacing apart dimension 326 can extend about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and/or 95 percent of the height of sheet 300′″ (e.g., length 322). In various embodiments ranges between any two of the above specified percentages can be used for limiting the extent of spacing apart dimension 326 extends along the height of sheet 300″″.

In various embodiments first and second plurality of openings 2200 and 2300 can extend along a substantial portion (although not its entire width) of a side (e.g., side 310 and of dimension 112). In various embodiments first and second plurality of openings 2200 and 2300 can extend about 50, 55, 60, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, and/or 100 percent of height of sheet 300″″(e.g., length 112). In various embodiments ranges between any of the two above specified percentages can be used the extension of the plurality of openings.

REFERENCE NUMERAL LIST REFERENCE NO. DESCRIPTION 10 cigar 20 tobacco filler material 22 arrow 53 arrow 54 arrow 55 arrow 56 arrow 60 arrow 61 arrow 62 arrow 70 moisture arrow 71 moisture arrow 72 moisture arrow 90 adhesive 100 smokable sheet 102 interior face 104 exterior face 110 edge 112 height of sheet on edge 110 114 dimension regarding depth of openings or perforations 116 dimension regarding depth of sheet not having openings or perforations 120 edge 122 length of sheet on edge 120 130 edge 140 edge 150 first end 160 second end 170 longitudinal opening 200 intermediate separating sheet 210 edge 220 edge 230 edge 240 edge 250 first end 260 second end 300 alternative smokable sheet 302 interior face 304 exterior face 310 edge 312 height of sheet on edge 310 314 dimension regarding depth of openings or perforations 316 dimension regarding depth of sheet not having openings or perforations 320 edge 322 length of sheet on edge 320 324 dimension regarding first length of sheet not having openings or perforations 326 dimension regarding depth of openings or perforations 328 dimension regarding second length of sheet not having openings or perforations 330 edge 340 edge 350 first end 360 second end 370 sealing tab 380 sealing tab 400 one or more pre-rolled sheet(s) 410 longitudinal opening or volume 430 arrows 440 arrows 600 form casing 700 packaging such as a pouch 710 flap (which can include a re-usable seal such as Zip-lock type seal) 750 carton or box 770 indicia and/or instructions 800 finished cigar 1000 plurality of openings or perforations 2000 plurality of openings or perforations 2200 plurality of openings or perforations 2300 plurality of openings or perforations 3000 user 3010 user's hand or finger or thumb 3020 user's hand or finger or thumb

It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. 

1. A method of making a custom made cigar comprising the steps of: (a) a consumer purchasing a sheet having first and second longitudinal edge portions; (i) a plurality of perforations in on one of the first and second longitudinal edge portions; and (ii) wherein sheet is packaged for sale in packaging in a rolled condition having an inner bore which is unfilled; (b) opening the packaging and removing therefrom the sheet; (c) unrolling the attached pre-rolled sheet wherein the pre-rolled sheet tends to roll back forming a cylinder having an inner volume; (d) adding a tobacco filler material to the inner volume; (e) closing the sheet such that first longitudinal edge portion covers the plurality of perforations on the second longitudinal edge portion, and thereby forming a custom-tailored cigar.
 2. The method of claim 1, wherein the packaging includes instructions related to steps “c” through “e”.
 3. The method of claim 1, wherein in step “a” the pre-rolled sheet is comprised of natural tobacco leaves.
 4. The method of claim 1, wherein in step “a” the pre-rolled sheet is comprised of homogenized tobacco.
 5. The method of claim 1, wherein in step “a” neither the first nor second longitudinal edge portions include adhesives.
 6. The method of claim 1, wherein in step “a” the plurality of perforations are in a straight line across the longitudinal length of the bore.
 7. The method of claim 1, wherein in step “a” the plurality of perforations form an irregular shape.
 8. The method of claim 1, wherein in step “a” the plurality of perforations form an zig zag shape.
 9. The method of claim 1, wherein in step “a” the plurality of perforations, before being sealed in step “e”, freely allow air flow through the perforations.
 10. The method of claim 1, wherein in step “a” the plurality of perforations, before being sealed in step “e”, are small enough so that air flow through the perforations is minimized, but large enough to allow a consumer to separate the perforations.
 11. The method of claim 1, wherein in step “a” the pre-rolled sheet is packaged for sale in a multiple sheet zip-wrapper packaging.
 12. The method of claim 1, wherein in step “a” the pre-rolled sheet is spirally wrapped about a supporting form casing.
 13. The method of claim 1, wherein in step “a” the pre-rolled sheet is spirally wrapped inside a supporting form casing.
 14. The method of claim 1, wherein in step “a” the pre-rolled sheet includes both a rectangular portion and a trapezoidal portion.
 15. The invention as substantially shown and described. 